XPTHC-

XPTHC-100

Manual of PLASMA Arc Voltage Controller

Shenzhen HongYuDa
HongYuDa CNC TECH Co.,LDT
Co.,LDT
H (SHENZHEN) CNC TECHNOLOGY CO., LTD
 Catalogue
、
1、 Brief Introduction/ Synopsis

、 Product Model …………………………………………………………4

1.1、

、 Chinese Name…………………………………………………………4
1.2、

、 Applied Scope ………………………………………………………….4

1.3、

、 Working Principle…………………………………………………..…4
1.4、

、 Basic Function…………………………………………………….……4
1.5、

、 Examination Method of Arc-Voltage………………………………5

1.6、

、
2、 Technique Parameter……………………………………………………….6

、
3、 Working Process ………………………………………………………..…7

、Method One………………………………………………………………..8
3.1、

、Method Two………………………………………………………………..8
3.2、

、
4、 Function of Panel Operation …………………………………………..…..9

、
5、 Voltage-Divided Board…………………………………………………….10

、Non-isolation Voltage-Divided…………………………………………10
5.1、

、Isolation Voltage-Divided …………………………………………..…11

5.2、

、
6、 IHS ………………………………………………………………………12

、IHS Check method of Torch Retain cap………………………12

6.1、

、Proximity Switch IHS Method of NPN、

6.2、 、PNP……….................14

、
7、 Interface Circuit ……………………………………………….….………15

、Power Supply Interface…………………………………………………15

7.1、

2
 、Up and Down Interface …………………………………………………15
7.2、

、Connect to Plasma Interface…………………………………….………17

7.3、

、Connect to CNC Control Interface……………………………………17

7.4、

、Proximity Switch IHS Interface ……………………18

7.5、

、Current Feedback Setting …………………………………….……… 18

7.6、

、
8、 Controlling Connection …………………………………………………...19

、Wiring diagram of Torch Retaining CAP with IHS ………………..19

8.1、

、Wiring Diagram of Proximity Switch with IHS……………………...20

8.2、

、
9、 Fault Maintenance………………………………………………………..21

、Frequent Fault Examination……………………………………………21

9.1、

、Cancel Extinguished Arc and Improve Function……………………22

9.2、

、 Several Proposal …………………………………………………..…23

9.3、

3
 、Brief Introduction
1、
、Product Model：
1.1、
XPTHC-100
、Chinese Name：
1.2、
弧压高度控制器
、Applied Scope：
1.3、
Apply to most of the import machine or state-owned machine because of the high
controlling of Plasma incision machine with the feature of constant current or the
feature of constant current in certain voltage scope.
、 Working Principle：
1.4、
The working principle of XPTHC-100 Plasma controller is using the constant
current of the Plasma power to attach the high controlling for the incision cutting torch
through checking the change of voltage to check the high changing of cutting torch in the
incision process.
、Basic Principle：
1.5、 ：
、 Automatic IHS：
A、 ：
Divide into checking method of Torch Retaining Cap IHS and Proximity
Switch IHS checking method which has NPN and PNP two types.
、 Anti-bump of Torch：
B、 ：
After cutting torch bumps into the steel plate in any condition, when examines the
electric circuit movement, will make the cutting torch promote to height.
、 Automatic High Controlling.
C、
、 Display the Monitoring Function Of the given arc voltage and the actual arc voltage:
D、
Arc voltage table demonstrates the given arc voltage before the Plasma arc
on, and Arc voltage table demonstrates the actual arc voltage after the process
of getting up the arc and perforation time delay .
、 All the function of above-water incision and under-water incision of automatic
E、
IHS method:The first invention from our company is under-water incision of Torch
Retaining Cap. The normal order has no special function about this except our
clients request it.
The cutting torch lifts
lifts and the Plasma gets up the arc when we have
no IHS:
IHS: When we don’t use the automatic IHS function we can make the cutting
torch reach the steel plate directly; When we carry on the arc operation,
the cutting torch can promote to be separated from the steel plate

4
 automatically and we can use SET-IHS to set the height above the steel
plate.
The function of boot-
boot-strap and cutting arc:
arc After the boot-strap and
cutting arc, In order to avoid the limit switch and the cutting car being
damaged, please note that the controller will make the cutting torch move
up for 2 seconds automatically When you debug.
、
F、 The Arc-voltage enables the output: Through setting the SET-PIERE potentiometer
on the panel, delay the output signal which is fulfilled by checking the existence of
arc voltage and which is the switch quantity.
、 Manual Operation Function: We can attain a lot of functions on the operation
G、
panel such as automation, manual-up&down,IHS
、 Automatic Operation: After the signal was given by the incision procedure, the
H、
arc-voltage complete the process: IHS—Starting Arc---Arc-voltage released the
signal. When the signal is accepted by CNC controller then the machine tool begin
to cut.
1.6 、The examination method of arc-voltage: Insulate and voltage-divided, the division
ratio is 100:1.

5
 、 technique parameter
2、

working voltage：
voltage：AC24V+
AC24V+5%，
5%，50Hz
50Hz/60H z

Down/Up Metor：
Metor：DC24V DC MOTOR

Drive:PWM
Drive:PWM

Output Current：
Current：1A-
1A-4A,

output power：
power：100W,
100W,

Working temperature：
temperature：-10∽
10∽60℃
60℃ adjusting-
adjusting-hei machine-
machine-10∽
10∽60℃
60℃

IHS method:
method:

Proximity switch IHS

IHS of Torch Retaining Cap

running transmission method:

method: Check the arc voltage to make sure fulfill the
ouput

Divide-
Divide-VOLT ratio :100:1

Precision ：±1V∽±
1V∽±5
∽±5V

shape
shape size ：length Xwidth X height：
height：320mmX2
20mmX260
mmX260mmX9
60mmX90
mmX90mm

The speed of upgrading

upgrading：：1000m
1000mm/min∽
min∽2000m
2000mm/min(
min(Contact the supplier if it
exceeds the range of speed）
speed）

6
 、 Working Process :
3、

、Method 1 :
3.1、
When the arc-beginning signal link with the 4th stitch of the 10 chip aviation socket, firstly,
the adjusting-height machine must be in a good IHS, then the machine reveal the power signal to
make the CNC controlling system work. And when the adjusting height machine display the
signal to the Plasma the arc voltage of the delay controller goes into adjusting height machine
system.

、Method 2 :
3.2、
When the arc-beginning signal link with the 5th stitch of the 10 chip aviation socket,
adjusting-height machine has no IHS but control the Plasma arc-beginning and the cutting torch at
the height of SET-HIS which can produce a signal to make the CNC system to do cut work.

,PS: When the CNC system can not receive the signal from

arc-beginning voltage you should control the CNC running by using

time-delay method.

7
 、 Function of Panel Operation
4、
Sketch map one of the panel
display arc-voltage fix on arc-voltage first height setting piere time Arc test

IHS-Test Auto/Manual Switch UP/Down

Figure 1:Panel

Arc Voltage：
Before the arc-beginning it shows the given arc voltage after it it shows the actual arc
voltage.
The arc voltage: Based the depth and speed of the incision material and the parameter
information we can find the arc voltage. The larger the arc voltage is given and the higher the
incision height will attain.
(Set IHS)： Increase the height through clockwise, the height is set by time-delay method.
From the re-set switch, every time we dial it up once, the checking IHS is given, which is
useful to examine whether it’s suitable for incision.
Set-piere: Set the time from Plasma to CNC controller starting, only the arc voltage can give
the signal.
：The adjusting-height machine is automatic, dial the switch at the location of
Auto/Manual：
automation, meanwhile, CNC controlling system and interface of adjusting height machine
start to work.
： From the re-set switch, still press it and wave up to make it work. The action is to
ARC-test：

8
 test the Plasma arc-beginning and move the cutting torch up at a certain IHS height.
： Move up and down by hand.
up/down：
ARCON ： When the lamp is bright it means that it is already start the arc, note: the ARCON
is dark until finish the signal and reach the IHS.
AUTO ： When the lamp is bright that is mean the adjusting-height machine is automatic,
getting the light bright must satisfy 4 requirements: 1, the automatic signal has been added; 2, the
automatic signal which connect with CNC system is work; 3, it has arc voltage introduced; 4,
actual arc voltage has not exceeded the arc voltage 30v. Note: the protection of over-voltage is
30v, it can be adjusted through RP104 according to customers’ actual requirements.
： When the lamp is bright it means arc voltage has been detected and the same time
TRANS：
send the working signal.

9
 、 Voltage-Divided Board
5、
We must check the movement of Plasma arc voltage when we do the controlling of arc
voltage. The voltage of Plasma arc must be same as the voltage between electrode and earth. The
positive port of Plasma power output should be connected with earth, the negative end should be
connected with electrode inside the cutting torch. So the voltage on the electrode is electronegative.
The absolute value of the arc voltage when do the incision exceeds 100v, so we must divide the
voltage in order to control in the circuit.
、 None Isolation Voltage-Divided
5.1、
The simplest way to divide the voltage is none-Isolation voltage-divided that is resistance
divide the voltage directly. Use the Figure below to divide the voltage since the XPTHC-100
already has a 1:1 circuit of voltage-divided.
Figure2: none-Isolation voltage-divided circuit

Figure 2: none-Isolation voltage-divided circuit

Note: The arc voltage which goes into adjusting-height machine is
electronegative, if the electrode is contrary, the automatic high adjusting is
ineffective.
As the method of none-Isolation voltage-divided is linked with Plasma power( can
not do the Isolation for the HF when the arc is introduced), so the disturbance for
the high adjusting machine is maximal, but the cost is the minimal.
During the practice work, as the arc voltage after voltage-divided is delayed to go to the
controlling circuit, the influence is very limited.
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 For the Plasma which touch the introduced arc voltage, it is no influence for the high
adjusting machine by using none-Isolation voltage-divided; when using the HF introduced
arc voltage increase the time of taking arc voltage to avoid the process of
introducing arc voltage.
、 Isolation Voltage-Divided
5.2、
Isolation voltage-divided machine has limited disturbance since it make the Plasma arc
voltage get the none Isolation voltage-divided of 100:1 and connect to high adjusting machine after
processed by Isolation circuit.
Diagram of working principle of Isolation voltage-divided machine.
AC220V Input - Actual arc voltage input +

100 ： 1
output none
quarantine
voltage-divi
ded

Output of Isolation voltage-divided

：Isolation Voltage-Divided Connection
Figure 3：

11
 Note: If you adopt the method of none Isolation voltage-divided, you can not use AC220V
power, use the 220v power when you adopt Isolation voltage-divided.
、 Initialization IHS
6、
Our company had designed two methods for high adjusting machine.

6.1、
6.1、 IHS Check method of Torch Retaining Cap。
Adopt this method require the metal construction for the Torch Retaining
Cap, so the metal can be electric with steel plate. XPTHC-100 has a piece of
Isolation IHS plate that can be fixed in the controller directly, the connection
way as Figure 4 below shows:

Connect earth

Connect workpiece
SHIELD

GND
WORK

Figure 4：
4：connection of Torch Retaining Cap HIS

12
 State：

A、 The TORCH RETAINING CAP port on the Isolation-IHS plate connect to the

Torch Retaining Cap directly through pressing-wire hole(label: TORCH RETAINING

CAP).

B、 The WORK port on the Isolation-IHS plate connect to the material-shelf

directly through pressing-wire hole(label: WORK).

C、 GND must be linked with earth perfectly, the area of earth lead must

exceeds 4 mm².

D、 When the Plasma without HF arc, the WORK and GND can be linked with each

other directly.

E、 Connect the JPT2 on the controlling plate to PNP when you adopt the method

of Torch Retaining Cap IHS. As Figure 5 shows(JPT1 was selected the mode of

IHS ,JPT2 was selected the type of Proximity Switch )

JPT1

JPT2

Figure 5：
5：JPT1 Setting of Slip Wire

Working Process of Torch Retaining Cap IHS：

IHS： After the high adjusting machine

receive the arc signal from the CNC system, the cutting torch come down immediately;

when the protection reach the steel plate, the high adjusting machine receive this signal

then control cutting torch to a setting height, when it finish, the high adjusting machine

control the Plasma arc automatically. You can adopt the touching-arc Plasma also HF arc

13
 Plasma. Both above water incision and under water incision are feasible. Note: You must

satisfy the following requirements when you use multimeter to measure the resistance

quantum of the water.

depth of measure：
measure：50mm

space between two pens：

pens：10mm

measuring resistance 〉1.5K

The parameter is decided by the examination in the salty water。

water。

6.2、 、PNP
6.2、Switch IHS Method of NPN、

All the IHS of Plasma no matter above-water or under-water incision can adopt this IHS
method.
You can check the clamp sketch map in appendix。

Before IHS, Proximity switch is in the situation of approaching, once depart,

the cutting torch will climb immediately。

working process：
process： After the high adjusting machine received the arc signal from CNC
system, the cutting torch descend at once and when it touch the steel plate the Proximity switch
will depart the approaching point then the high adjusting machine receive the signal to make the
cutting torch at a setting certain height. This way is suitable for all the IHS of Plasma.
Proximity switch connect to the Proximity switch through SWITCH-HIS in the high

adjusting machine.

Note: NPN method: Insert the JPT1 slip stitch in the location of NPN, the similar

as PNP insertion for JPT1.

14
 、 Interface Circuit
7、
Figure 6 shows the mainboard sketch map

TO-TORCH TO-CNC SWITCH-IHS GND （AC24V）

POWER（ ）

TO-PLASMA WORK TORCH RETAINING CAP

：Mainboard Sketch Map

Figure 6：

、 Power Supply Interface。

7.1、

The power supply of the XPTHC-100 is AC 24V, connect to JP1 of the high adjusting
machine by using “power” aviation socket.

、 Up and Down Interface。

7.2、

15
 Figure 7 shows the generator output.

CON-GUN

JP7-1

JP7-2

：Generator Output
Figure 7：
Figure 8 shows the Up and Down interface connection.

JP7-4

JP7-3

：Upper limit /lower limit digit connection

Figure 8：
Note: the limit switch should connect the NC
、
7.3、 Connect to Plasma Interface
The 4-chip socket of TO-PLASMA connect the JP5 port. The connection of Plasma as Figure
9 shows:

16
 负电压

Figure 9：Mainboard Plasma connection

Connect to CNC Control Interface

JP6

：connection of high adjusting machine and CNC control

Figure 10：

The connection of high adjusting machine and CNC control introduce the Isolation
method of photoelectricity, it has 6 ports as below respectively:
A、 (EXAUTO) Auto/Manual： The lower storage battery is automatic and the higher one is
manual。
B、UP： Lower storage battery is up.

17
 C、DOWN：Lower storage battery is up.
D、IHSARCON：Lower storage battery is work, but first we must do the IHS, the JP6 has
finished the automatic arc-beginning.
E、EXARCON：Lower storage battery is work, start the arc directly. Make sure the incision
gun approach steel plate then do the arc-beginning.
F、ARCTRANS1、ARCTRANS2：On-Off quantum send signal.

、Proximity Switch IHS Interface

7.5、

As Figure 11 shows: Connect to JP3 Port through 3 chip aviation socket( label：switch HIS)

JP3

：Proximity switch connection of IHS

Figure 11：

、 Current Feedback Setting。

7.6、

Current 1-8 2-7 3-6 4-5

4A ：PWM=9KHZ
OFF： OFF OFF OFF
3A OFF OFF ON
2A ：PWM=18KHZ
ON： OFF ON ON
1A ON ON ON

18
 、 Controlling Connection
8、
、 IHS Wiring Diagram of Torch Retaining CAP
8.1、

19
 、IHS Wiring Diagram of Switch
8.2、

20
 、Fault Maintenance
9、
、Frequent Fault Examination
9.1、
Serial Malfunction Cause Resolution
Number
1 No display, black No +5V voltage on the Check +5V voltage VCC3
screen voltage meter
2 No revolution of 1、 damage of drive 1、replace IR2110
generator or only IR2110
one direction 2、 drive voltage +15V， Check drive voltage VCC4
rotates. failure

3、 protection of D606 ∽ D609 （ IRF640 ） is

over-current damaged or mechanical
blocked
3 Once open the 1.Proximity switch is Install the Proximity
power, the incision not installed well in switch perfectly
part continue to the open-circuit
move up 。（NPN） condition
2、damage of Proximity Replace Proximity switch
switch （signal：2mm，NPN）
4 Can not produce arc 1、damage of Proximity Replace Proximity switch
automatically switch, no return
after the IHS signal
2 、 IHS time is too Prolong the IHS switch
short, no return signal
5 Instability of 1、check the connection with earth
controlling voltage 2、check the air-proof
3、over-sensitiveness

21
6 The machine start to Setting time of 1、increase SET-PIERE time
work before the SET-PIERE is too short 2、adopt the arc feedback signal
accomplishment of of Plasma itself
arc-beginning
7 Plasma produce arc When we use the Prolong the delay time of CNC
before the IHS EXARCON signal, the IHS
delay-time of CNC
controlling is too short
8 Cutting torch can not 1、Confirm the working situation of Plasma power
produce arc 2、Check the height of IHS
3、Check the cutting torch fittings
9 Plasma cutting torch 1、Check the connection of working lead
can not transfer to 2、Check the cutting torch fittings
workpiece
10 Cutting torch move Prolong the time of piercing hole in the CNC system
before the fulfillment
piercing hole
11 The CNC control start 1、Increase the setting of “given voltage”
move, the cutting 2、Prolong the automatic time in the CNC system
torch then begin work 3、Decrease the setting of over-voltage

4、Check the situation of automatic signal or cornering signal

of CNC system
12 Plasma arc out after 1、 Delay-time is too long
the arc transferring
and piercing hole
13 When do the IHS, the 1、Time of HIS is too short
cutting torch touch the 2、Induced lead connect with protection badly
steel plate but no
movement upwards.

14 Cutting torch still 1、Bad checking cable and contact of the Torch Retaining
press the steel plate Cap
downwards and no 2、Proximity switch is damaged
arc-producing 3、“WORK” in the high adjusting is bad connection with
earth

22
15 Cutting torch is 1、High sensitiveness of high adjusting machine，regulate
unsteadily in RP501
automation 2、damage of high adjusting machine
16 High adjusting 1、High sensitiveness of high adjusting machine，regulate
machine is too slow to RP501
follow in automation
17 No arc during the cause：can not stop immediately since the high adjusting
incision, the are machine is are voltage signal.
voltage is continued to resolution：adopt the arc feedback signal of Plasma itself
produce and the
machine is still work

9.2、
9.2、Cancel Extinguished Arc and Improve Function：

If the ascending function of cutting torch has not been installed properly

the down-up is easy to block by boot-strap, you can cancel the function in the

main control board.

There are two ways to cancel the function:

1、Cancel the R234 in the main board

2、Cancel the C218 in the main board

9.3、
9.3、Several Proposal

1、When we use the IHS of Torch Retaining Cap, install the anti-bump clamp

and connect to protect the Torch Retaining Cap, in this way it is more useful

to safeguard the cutting torch.

2、When we use the Proximity switch, we suggest to use the PNP model. The

ways as below shows:

23